Method of assembling a vehicular camera having coaxial connector

ABSTRACT

A method of assembling a vehicular camera includes providing a front housing portion and a rear housing portion and attaching a circuit board at the front housing portion. A one-piece coaxial connecting element is provided at the rear housing portion. With the coaxial connecting element provided at the rear housing portion, a first coaxial cable connector extends outward from the outer side of the rear housing portion and a second coaxial cable connector extends inward from the inner side of the rear housing portion. As the rear housing portion is mated with the front housing portion, the second coaxial cable connector engages the third coaxial cable connector at the circuit board to electrically connect the coaxial connecting element with circuitry at the circuit board. The first coaxial cable connector is configured to connect to a coaxial cable of a vehicle when the vehicular camera is disposed at the vehicle.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 16/186,867, filed Nov. 12, 2018, now U.S. Pat. No. 10,367,281,which is a continuation of U.S. patent application Ser. No. 15/062,524,filed Mar. 7, 2016, now U.S. Pat. No. 10,128,595, which claims thefiling benefits of U.S. provisional applications, Ser. No. 62/217,118,filed Sep. 11, 2015, Ser. No. 62/204,166, filed Aug. 12, 2015, Ser. No.62/164,619, filed May 21, 2015, Ser. No. 62/154,396, filed Apr. 29,2015, and Ser. No. 62/130,130, filed Mar. 9, 2015, which are herebyincorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present invention relates generally to a vehicle vision system for avehicle and, more particularly, to a vehicle vision system that utilizesone or more cameras at a vehicle.

BACKGROUND OF THE INVENTION

Use of imaging sensors in vehicle imaging systems is common and known.Examples of such known systems are described in U.S. Pat. Nos.5,949,331; 5,670,935 and/or 5,550,677, which are hereby incorporatedherein by reference in their entireties. In high speed digital datatransmission in automotive applications, such as sensors or displays orinfotainment systems, shielded coaxial cable is used for its excellentisolation of the signal and ground path from each other, and fromelectromagnetic interference (EMI) issues with adjacent electricalcomponents. The device's PCB typically contains a coaxial header asshown in FIG. 1, and the device's housing would have a mating jack toengage this header. This method of connection to the PCB requiresintricate machining, casting, or stamping operations which increase costand reduce design flexibility.

SUMMARY OF THE INVENTION

The present invention provides a vision system or imaging system for avehicle that utilizes one or more cameras (preferably one or more CMOScameras) to capture image data representative of images exterior of thevehicle, and provides enhanced electrical connection between a coaxialconnector and circuitry of a printed circuit board of the camera. Theconnection of the present invention provides a ground clamp that clampsto ground pins of the connector portion of the housing of the camera andthat clamps to a ground shield at the header of the printed circuitboard when the camera is assembled. The connection thus providesenhanced grounding and enhanced electrical connection of the connectorportion to the PCB circuitry, thereby providing enhanced datatransmission, such as for high speed data transmission applications.

According to an aspect of the present invention, a camera for a visionsystem of a vehicle includes a front housing portion having a lensbarrel or lens holder and a rear housing portion having a connector forconnecting to a coaxial vehicle wire harness when the camera is disposedat the vehicle. The connector comprises a signal pin and at least oneground pin or contact (such as two ground pins or contacts, one at eachside of the signal pin). The rear housing portion includes a clampingelement in electrically conductive connection with the ground pins andelectrically isolated from the signal pin. The camera includes a circuitelement (such as a printed circuit board or PCB at the front housingportion) having circuitry established thereat. The circuit elementcomprises a connector header and an electrically conductive shielddisposed at least partially around the connector header and inelectrical connection with circuitry of the circuit element (such as viasoldering of the connector header at circuitry or traces of the circuitelement). The clamping element is configured to engage the electricallyconductive shield when the signal pin and the ground pins engage theconnector header during assembly of the camera, and wherein connectionof the clamping element and the electrically conductive shield providesenhanced grounding of the ground pins of the connector with circuitry ofthe circuit element.

These and other objects, advantages, purposes and features of thepresent invention will become apparent upon review of the followingspecification in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art coaxial connector;

FIG. 2 is a plan view of a vehicle with a vision system thatincorporates cameras in accordance with the present invention;

FIG. 2A is a perspective view of a camera in accordance with the presentinvention;

FIG. 3 is a perspective view of a printed circuit board of a device,shown with a metal shield at and at least partially around a headerconnector in accordance with the present invention;

FIG. 4 is a perspective view of a rear housing portion of a device, suchas a camera, shown with a spring clamp at the ground pins of theelectrical connector of the housing portion in accordance with thepresent invention;

FIG. 5 is an enlarged perspective view of the spring clamp and connectorpins of the rear housing portion of FIG. 4;

FIG. 6 is a sectional view of the rear housing portion, showing theelectrical connection being made between the pins and the header portionand between the spring clamp and the metal shield in accordance with thepresent invention;

FIG. 6A is an enlarged view of the area A in FIG. 6;

FIGS. 7-9 show different views of the crimp ferrule in accordance withthe present invention;

FIG. 10 is a sectional view of the crimp ferrule of FIGS. 7-9;

FIG. 11A shows a sectional view of a spring-loaded telescopic pin forbeing assembled at the coaxial cable core wire by putting the core wireinto the core wire slot, before soldering, welding, or crimping;

FIG. 11B shows a coaxial cable with the spring loaded telescopic pin(pre-) assembled to the coaxial cable's core pin and the crimp ferruleapplied to the coaxial shield without the additional dielectric element;

FIG. 11C is a sectional view of the assembly of FIG. 11B;

FIG. 12 shows the coaxial cable of FIG. 11B with the dielectric elementadded (in preassembly) which holds the core pin centered when insertedto the camera core pin channel;

FIG. 13A is a sectional view of the full coaxial cable assemblyaccording to the present invention which is already inserted (finalapplication) to the camera housing;

FIG. 13B is an enlarged sectional view of the cable assembly andconnection of FIG. 13A;

FIG. 14A is a rear perspective view of a camera housing structure havinga coaxial connector interface of the present invention and additionallya four pin interface combined in one connector, showing the inside ofthe rear housing connector structure;

FIG. 14B is a view of the camera housing of FIG. 14A, showing a frontalview of the inside of the rear housing connector structure having acentering ring for the coaxial cable's core, a screw hole and holes forfour pins;

FIG. 14C is another view of the camera housing of FIG. 14A, showing arear view onto the outside of the rear housing connector structurehaving a centering ring for the coaxial cable's core and holes for fourpins;

FIG. 14D is a perspective view of the rear housing of FIGS. 14A-C, shownwith the coaxial cable applied;

FIG. 14E is a perspective view of the rear housing of the connector andcable assembly of FIGS. 14A-D, shown with the camera rear housing andapplied coaxial cable section overmolded;

FIG. 15A is a sectional view of a camera's rear housing structure usinga coaxial cable interface in accordance with the present invention,having a spring loaded pin (pogo pin) and a sheath as dielectric and forcentering the core pin;

FIGS. 15B and 15C are enlarged sectional views showing additionaldetails of the structure of FIG. 15A;

FIG. 15D is a sectional view of a camera's rear housing structure ofFIG. 15A, shown with the camera rear housing and applied coaxial cablesection overmolded, similar to FIG. 14E;

FIG. 16 is a sectional view of an alternative crimp ferrule whichextends over the full length for acting as an uninterrupted shield, witha sheath as dielectric and for centering the core pin;

FIG. 17 is a sectional view similar to FIG. 16, additionally showing thefixation screw;

FIG. 18 is a side elevation of a cable showing the layers of a LeoniDacar 462 coaxial cable (1 core, 2 dielectric, 3 shielding foil, 4shielding meshwork, 5 sheath), with the shielding meshwork is to befolded back over the sheath before the crimp ferrule gets assembled overit;

FIG. 19 shows the Leoni Dacar 462 coaxial cable with a crimp ferrule (orsleeve) assembled over the folded back shielding meshwork;

FIG. 20 is a partial sectional view of the crimp area when the crimpferrule gets crimped;

FIG. 21 shows the crimp area when the core pin gets crimped to thecoaxial cable's core;

FIG. 22 shows a partial sectional view of the crimp area of the flexiblepin as finding use for being assembled to the coaxial cable's core inaccordance with the present invention;

FIG. 23 is a side elevation and partial sectional view showing theinsertion direction of the preassembled cable into the housing channel,with the housing shown as a sectional view;

FIG. 24 is a side elevation and partial sectional view of the fullyinserted coaxial cable with flexible pin inside the housing's channel;

FIG. 25 is a side elevation of the camera rear housing with the coaxialcable assembly of the present invention with overmold;

FIG. 26A is a side elevation and partial sectional view of a coaxialcable connector suitable for use with the connection system of thepresent invention, with FIG. 26A showing a FAKRA Rosenberger59K130-102A4 coaxial cable connector;

FIG. 26B is a perspective view of the connector of FIG. 26A;

FIG. 26C is a coaxial cable connector similar to that of FIGS. 26A andB, shown with modified flanges for enabling the use for press fitmounting;

FIG. 26D is a coaxial cable connector similar to that of FIGS. 26A-C,shown with having an SMP Rosenberger connector interface with modifiedflanges for enabling the use for press fit mounting;

FIG. 27 is a perspective rear view of a camera rear housing with a pressfit modified connector connected thereto;

FIG. 28 is a perspective front view of a camera rear housing with apress fit modified connector connected with the flexible elements of thecoaxial connector's shield skirt and core shell visible, shown with fourflexible non-coaxial press fit pins having a laterally flexible portion(by a spring);

FIG. 29 is a sectional view of a readily assembled camera (but withoutthe overmold), with the coaxial cable plug reaching out of the camera'srear housing into the PCB coaxial SMD header of FIG. 30, the coaxialcable connector of FIG. 26C and some of the four non coaxial springcontacts of FIG. 28 visible;

FIG. 30 is a known Rosenberger SMD coaxial SMD header, No. 17S101-40ML5;

FIG. 31 is a modified PCB coaxial SMD header similar to the header ofFIG. 30, but with the shield contact's shoulder pulled up for smoothingthe resting depths of the counter connector;

FIG. 32 is a sectional view of a readily assembled camera with theovermold for tightening and pull relief, with the coaxial cable plugreaching out of the camera's rear housing into the (modified) PCBcoaxial SMD header of FIG. 31 in use;

FIG. 33A is a perspective view of a camera rear housing similar to FIG.28, with the coaxial connector part shown from inside the camera rearhousing after attaching by press fit (in this case from outside);

FIG. 33B is a perspective view of a camera rear housing similar to FIG.33A, with the connector SMD counter piece shown as it will interconnectwith the rear housing upon assembly (but with the PCB not shown), withthe SMD counter piece meant to be placed on the PCB;

FIG. 33C shows the ‘pick and place’ aiding device for mounting the SMDconnector mating pieces onto the PCB during assembly and reflow;

FIG. 33D is a perspective view of the connector side of the SMD counterpiece shown from the SMD side in FIG. 33C;

FIG. 33E is a perspective view of the bundled connector SMD counterpiece similar to FIG. 33C, but with the bridges on the side for havingspace in the middle to embrace a wall of the housing with conductingsurface having ground potential; and

FIG. 34 is a sectional view of a readily assembled camera with theovermold for tightening and pull relief, with the coaxial cable plugextending out of the camera's rear housing into the (modified) PCBcoaxial SMD header pin slot bundle assembled on it.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A vehicle vision system and/or driver assist system and/or objectdetection system and/or alert system operates to capture images exteriorof the vehicle and may process the captured image data to display imagesand to detect objects at or near the vehicle and in the predicted pathof the vehicle, such as to assist a driver of the vehicle in maneuveringthe vehicle in a rearward direction. The vision system includes an imageprocessor or image processing system that is operable to receive imagedata from one or more cameras and provide an output to a display devicefor displaying images representative of the captured image data.Optionally, the vision system may provide a top down or bird's eye orsurround view display and may provide a displayed image that isrepresentative of the subject vehicle, and optionally with the displayedimage being customized to at least partially correspond to the actualsubject vehicle.

Referring now to the drawings and the illustrative embodiments depictedtherein, a vehicle 10 includes an imaging system or vision system 12that includes at least one exterior facing imaging sensor or camera,such as a rearward facing imaging sensor or camera 14 a (and the systemmay optionally include multiple exterior facing imaging sensors orcameras, such as a forwardly facing camera 14 b at the front (or at thewindshield) of the vehicle, and a sidewardly/rearwardly facing camera 14c, 14 d at respective sides of the vehicle), which captures imagesexterior of the vehicle, with the camera having a lens for focusingimages at or onto an imaging array or imaging plane or imager of thecamera (FIG. 2). The vision system 12 includes a control or electroniccontrol unit (ECU) or processor 18 that is operable to process imagedata captured by the cameras and may provide displayed images at adisplay device 16 for viewing by the driver of the vehicle (althoughshown in FIG. 2 as being part of or incorporated in or at an interiorrearview mirror assembly 20 of the vehicle, the control and/or thedisplay device may be disposed elsewhere at or in the vehicle). The datatransfer or signal communication from the camera to the ECU may compriseany suitable data or communication link, such as a vehicle network busor the like of the equipped vehicle. As shown in FIG. 2A, the camera 14includes a first or front housing portion 22 that includes a lens orlens assembly 24, and further includes a second or rear housing portion26 that has a connector portion 28 for electrically connecting to orreceiving one or more connecting ends of wires of the vehicle when thecamera is disposed at a vehicle, as discussed below.

In accordance with the present invention, the data transfer is made viaa coaxial connection to circuitry of the camera or control. Low speedanalog transmissions may be handled by discrete wires which are routedto individual pin headers (such as by utilizing aspects of the systemsdescribed in U.S. Publication No. US-2013-0328672, which is herebyincorporated herein by reference in its entirety). These pin headers arecommonly available, and may be manufactured with simple low costcomponents. When attempting to transmit digital signals through thistype of header, the transmission may be compromised due to EMI or RFLeakage.

The present invention outfits an analog style connector system withnovel features to achieve performance on-par with the more expensivecoaxial connectors in high speed digital data applications. Theconnection of the present invention may electrically connect a coaxialwiring connector to a printed circuit board of a device, such as acamera of a vehicle vision system. The connection and camera may utilizeaspects of the connections and cameras described in U.S. Pat. No.8,866,907 and/or U.S. Publication Nos. US-2013-0328672; US-2014-0320636;US-2013-0222595; US-2013-0344736; US-2014-0373345 US-2013-0242099 and/orUS-2015-0222795, which are all hereby incorporated herein by referencein their entireties.

As shown in FIG. 3, a printed circuit board (PCB) 30 includes an analogheader 32 surrounded by a metal header shield 34 that is soldered to thePCB. The metal shield is designed to retain to the header such that thetwo can be placed in one pick-and-place step in the SMT (surface-mounttechnology) process as used for stuffing components onto a circuit boardduring manufacture of electrical circuitry. This component would be madeof any conductive material, and may or may not be plated. The printedcircuit board includes circuitry of the device, and may includecircuitry on both sides of the board or substrate, such as imagercircuitry of a camera, where the PCB may be disposed in a camerahousing, with a front camera housing including a lens support or barreland a rear camera housing portion having an electrical connector forconnecting to a vehicle wiring harness. The circuit board or boards maybe attached at the front or rear housing, and when the camera isassembled together, the connector at the rear camera housing portionmakes electrical connection to circuitry or connectors at the rearsurface of a rear circuit board of the camera. The circuit boardincludes circuitry associated with the imager or imaging array, and thecircuit board at the connector may be electrically connected (such asvia a flexible connector or ribbon cable or the like) to a second orstacked circuit board of the camera, with the second circuit boardincluding the imager or imaging array of the camera or camera module.

As shown in FIGS. 4 and 5, the rear camera housing portion 36 includes aconnecting portion 38 for connecting to a vehicle wiring harness or thelike. A spring shield or clamp 40 is disposed at the rear camera housingportion 36 and comprises a series of clamp features which engage theground pins 42 of the connector of the device, a center hole to avoidthe signal pin 44. The spring shield 40 includes clamp features which,when the connector is connected to the header 32 of the PCB 30 (such asshown in FIGS. 6 and 6A), bear against the header shield 34 to create acontinuous ground path to the PCB, to shield the center pin 44 in allrelative positions of the PCB and housing, and to protect againstexternal EMI. Thus, when the spring shield and connector are pressedinto engagement with the PCB header, the pins 42, 44 are received intheir respective receivers of the header (such as shown in FIG. 6A,where the signal pin 44 is received in and electrically connects to areceiving portion 46 of the header 32) while the spring shield 40engages and clamps onto and electrically conductively connects to theheader shield 34 at the circuit board 30.

The pin clamps are designed such that the shield can be applied at therear housing portion and at the ground pins 42 with a press, butprovides a high retention force. The clamps that engage the headershield 34 are shaped such that they guide the header into positionbefore the three pins 42, 44 engage the respective parts or receivers ofthe header 32 at the PCB 30. For example, and such as shown in FIGS. 6and 6A, the walls of the spring shield 40 are flared or curved outwardlysuch that any misalignment between the spring shield and the headershield during connection of the parts is accommodated by flexing andguiding of the spring shield walls as the spring shield and headershield are pressed together. The spring shield 40 may be made of anyconductive spring material, such as, for example, and not limited to,beryllium copper, phosphor bronze and/or stainless spring steel.Optionally, the spring shield may or may not be plated.

Therefore, the present invention provides a connector with enhancedground connection between the connector at the rear housing portion andthe circuitry at the PCB of the camera or device. The spring clamp iselectrically conductively connected to the ground pins of the connectorand is configured to flex and clamp onto an electrically conductiveshield at and around the header at the PCB when the electrical connectoris connected or plugged into the PCB header (such as during assembly ofthe camera or device). The spring clamp and header shield of the presentinvention thus provide enhanced electrically conductive connection orground connection to the circuitry of the PCB, while easing alignmentand assembly of the connector to the PCB header during assembly of thecamera or device.

Thus, the clamping element may comprise a metallic element that is pressfit attached to the ground pins. The clamping element may comprise anysuitable number of flexible walls (such as, for example, four flexiblewalls) that are biased towards a position where the flexible wallsengage and clamp onto the electrically conductive shield when the camerais assembled. The flexible walls are preferably configured to guide oralign the clamping element with the electrically conductive shieldduring assembly of the camera.

Optionally, and with reference to FIGS. 7-25, the camera is configuredto electrically connect to a coaxial cable connector. Such coaxialcables fulfill various functions, such as for an Ethernet connection.Transmission of video data over coaxial cabling and utilizing theconnectors of the present invention has several advantages, includingenhanced protection against hacking or corruption due to cyber-attacksand the like on a vehicle equipped with the vehicle cameras andconnection system of the present invention. For example, in a surroundvision system comprising at least three vehicle cameras, it is preferredto use Ethernet cabling and the connection system of the presentinvention for transmission of image data captured by the respectivevideo cameras of a vehicular multi-camera surround vision system to acentral ECU where video manipulation and image stitching can beperformed to generate a composite bird's eye or top view or panoramicview image for display to a driver of the equipped vehicle. Ethernetequipped vision systems that benefit from the vehicle cameras andconnecting system of the present invention include systems of the typesdescribed in U.S. Pat. Nos. 9,126,525; 9,041,806 and/or U.S. PublicationNos. US-2015-0042807; US-2014-0340510; US-2014-0218535 and/orUS-2012-0218412, which are hereby incorporated herein by reference intheir entireties.

The coaxial connector 144 of the present invention includes a flexiblecore pin 146 attached to a coaxial cable's core wire and provided toextend or reach through the rear camera housing 136 and the camera'shousing contour to engage or electrically connect and conduct at anelectrical contact connector pad or trace or receiver 130 a at acamera's PCB 130 (see FIG. 13A). The electrical contact 130 a maycomprise a connector pad or electrically conductive trace established atthe circuit board, or may comprise a socket or receiver or electricalcomponent disposed at the circuit board. The flexible core pin of FIG.11A is preassembled to the coaxial cable's core conductor such as shownin FIGS. 11B and 11C. The flexible pin is held and centered by adielectric component 150 (see FIG. 12), which itself is attached to thecoaxial cable by a crimp ferrule 152 which additionally has the task toconduct the coaxial shielding (see FIGS. 13A and 13B). During assemblyto the coaxial cable, the coaxial cable shield is folded back over thesheath (see FIG. 18) and the crimp ferule pushed over it (see FIG. 19).Optionally, the ferule fixation is additionally enforced by crimping(see FIG. 20). The center pin's root slot may be attached to the coaxialcable's core wire by crimping (FIG. 21), soldering or welding.Optionally, it may be attached by having an inner flange made forpartially cutting a tread into the core wire for mechanical attachingand electrical conducting, without having the need of further treatmentslike soldering or crimping. Optionally, and such as shown in FIG. 16,the crimp ferule may extend all the way to the PCB to make electricalcontact therewith, and a dielectric sheath may be provided between thecore pin and the ferule to limit lateral movement or flexing of the corepin within the elongated ferule.

Thus, the coaxial connector of the present invention makes affirmative,robust and reliable electrical connection between a coaxial cable andcircuitry of the circuit board when the spring biased connector end isurged against a circuit element (such as a pad, receiver or trace or thelike) established or disposed at the rear surface of the substrate ofthe PCB.

The connector of the present invention may utilize aspects of theconnectors described in U.S. Publication No. US-2015-0222795, which ishereby incorporated herein by reference. The coaxial connector solutionattaches a coaxial cable to a vehicle camera's housing and PCB. Theconnector may use non air dielectric within the coaxial connector, seeFIGS. 12, 13A, 13B and 16. PCB pins which have either flexible(bendable, spring like, such as shown in close up of FIGS. 13B and 15B)properties or fixed pins which insert into a socket with depthsindependent contacts may be used, such as described in U.S. PublicationNo. US-2015-0222795.

The direct assembly of the coaxial cable to the camera housing withouthaving an outbound housing connector is done by having a slot in thehousing wall which is metallized or coated with a conducting materialfor receiving the coaxial cable's shielding (or a shielding (crimp-)ferule) and with the coaxial cable's core contact having a preassembledlaterally flexible PCB contact which gets inserted into a housing'schannel toward the PCB sitting in the camera housing may be utilized,such as described in U.S. Publication No. US-2015-0222795. An optionalcrimp shell (such as shown in FIGS. 7-10, 11B and 12) may be providedfor holding and conducting the coaxial cables shield 3 and the shieldingmeshwork 4 during or prior to camera assembly, such as by utilizingaspects of the connectors described in U.S. Publication No.US-2015-0222795. The centering contact carrier may optionally be part ofthe housing structure, such as can be seen with reference to FIGS. 14Band 14C. An optional contact carrier may hold the core contact in thecenter of the housing channel, such as by utilizing aspects of theconnectors described in U.S. Publication No. US-2015-0222795. Theselection of an optimal radius of the (round) shield inner surface andthe core pin outer surface, so the distance of both is in accordancewith the chosen dielectric, may be provided, such as by utilizingaspects of the connectors described in U.S. Publication No.US-2015-0222795.

Optionally, the coaxial cable structure with flexible pin andshielding—crimp ferule of the present invention may be paired withdifferent connector types, such as connectors having a single pin, suchas shown in FIGS. 3-6A, or multiple pins having a common circumferentialshielding or one shielding each. Examples of such a pairing is shown inFIGS. 14A-D and 25. For example, and such as shown in FIG. 14A, the rearcamera housing 136 may include a connector portion 154 that has acylindrical portion 154 a through which the flexible end or pin 146 ofthe coaxial connector may extend, and the connector portion 154 alsoincludes a multi-pin connector portion 154 b that receives the pins orterminals of a multi-pin connector (such as described above), which maythen electrically connect to terminals and circuitry at the circuitboard. The flexible pin of the coaxial cable connector and the terminalsof the multi-pin connector may connect to circuitry elements at the PCBduring assembly of the camera, such as discussed above. The shield ofthe single pins may optionally be done by metallization of the camerarear housing inner wall next to the to-be-shielded pin. Depending on theapplication, the outbounding cables may be overmolded as can be seen inFIGS. 14E and 25, such as for tightening and pull relief purposes. FIGS.23 and 24 show the insertion steps when assembling the preassembledcoaxial cable structure with flexible pin and shielding—crimp ferule tothe camera housing. The ferule's contour is made for plugging into thecamera housing's coaxial cable slot inner wall contour (such as withinthe cylindrical receiving portion 154 a), with the flexible pinextending from the ferule and from the cylindrical connector portion toengage circuitry (such as an electrically conductive pad or trace orelement) at the circuit board when the camera is assembled. Optionally,the inner wall of the cylindrical receiving portion 154 a may optionallybe metallized or otherwise electrically conductive to electricallyconnect with the metallic ferule when the ferule is pressed into thereceiving portion, and the metalized inner wall may electricallyconductively connect with circuitry at the circuit board when thecircuit board is disposed at the rear housing portion (such as can beseen with reference to FIGS. 13A and 13B). In such a configuration, theannular surface 155 (FIG. 14A) of the cylindrical receiving portion 154a is also metalized so that electrical connection between the ferule andcircuitry at the circuit board is made via engagement of the annularsurface 155 to one or more electrically conductive traces or pads or thelike at the circuit board when the camera is assembled.

Thus, the connector or connectors of the rear housing portion may bemolded with the housing portion and includes a multi-pin connectorportion and a coaxial connector portion. The multi-pin connector portionreceives multi-pin connector terminals therein, and the terminals (whichmay be pins or receiving elements for receiving pins) engagecorresponding terminals (such as receiving elements or pins or circuitryelements) at the circuit board when the circuit board is moved intoengagement with the terminals. The circuit board may include a headershield and the connector portion may include a spring shield or clampthat, when the connector is connected to the header shield of the PCB,bear against the header shield to create a continuous ground path to thePCB, to shield the center pin in all relative positions of the PCB andhousing, and to protect against external EMI, such as discussed above.The connectors (including the multi-pin connector portion and thecoaxial connector portion) may be formed adjacent to one another or aspart of a single connector, or may be formed separate from one anotheras separate and distinct connectors of the camera housing.

The coaxial connector portion receives a coaxial connector therein, withan extended core pin of the coaxial connector extending to contact acircuit element at the circuit board, and with the crimped ferule of thecoaxial connector being press fit or interference fit within the coaxialconnector portion. The inner surface of the coaxial connector portionmay be metalized or otherwise electrically conductive, with thatmetalized surface being in electrical connection with a circuit elementat the circuit board when the camera is assembled together. Optionally,and desirably, due to the extended length of the core pin from theferule, a dielectric element may be disposed along the core pin andwithin the coaxial connector portion to limit lateral flexing of thecore pin and shorting of the core pin at the electrically conductive ormetalized inner surface during assembly of the camera and during useover the lifetime of the camera at a vehicle. The core pin may comprisea spring-loaded core pin to enhance electrical contact and connection atthe circuit element of the circuit board when the camera is assembled.

Optionally, and with reference to FIGS. 26-29, a coaxial cable plugstructure (such as a FAKRA Rosenberger 59K130-102A4 or SMP (such as aRosenberger 99K15K-102A5) such as shown in FIGS. 26A and 26B) may have amodified flange (see FIGS. 26C and 26D) for enabling mold material pressfit, preassembled to an outbound coaxial cable that may reach throughthe housing, and may be inserted by press fit, having a laterallyflexible shielding skirt which is divided into circular segments toadapt to a mating solid PCB carrier structure having a solid shieldingring, such as by utilizing aspects of the connectors described in U.S.Publication No. US-2015-0222795. The press fit plug structure also has alaterally flexible shell in its center to mate with a solid core pinreaching out of the PCB header structure.

Different from the connectors described in U.S. Publication No.US-2015-0222795, in this optional solution neither the core contact northe shielding contact on the PCB carrier has flexible properties butboth contacts (shielding skirt and core pin) of the press fit coaxialconnector reach from the housing towards the PCB carrier (shown in FIGS.33B, 33C, 33D and 33E) or PCB coaxial slot (shown in FIGS. 30 and 31).Optionally, the area encircled by the PCB carrier's shield may be filledby air (or there may be a vacuum in applications where the camera may beencapsulated or air tight and assembled in a vacuum) or by a flexibledielectric material, such as a compressible or flexible foam, paste orgummy with a hole in the middle for the core pin. The examples of FIGS.27 and 28 additionally show four additional non-coaxial press fit datapins, each of which has vertically flexible (spring) properties (FIG.28) reaching onto a PCB pad, at which a conducting pad is applied at.The pads as well as the spring contacts may have a gold or silversurface for avoiding wear. A cross section of a full assembly of such aconfiguration is shown at FIG. 32. As an alternative more misalignmenttolerant solution, the non-coaxial pins may be fixed pins reaching intoa socket header with lateral flexible properties in which the contactsdive with flexible depths (FIG. 33A). The counter piece (of FIG. 33D),such as, for example, an SMD counter piece (connector mating piece), ismeant to be placed on the PCB of FIG. 33B. A slightly modified versionof the SMD header pin slot—coaxial slot bundle of FIG. 33D is shown inFIG. 33E. A similar alternative solution with two (different) matingpieces may be mounted under use of an additional pick and place aidingpart (shown in FIG. 33C), which ensures the correct distance andorientation when placing the SMD counter connector (mating) parts ontothe PCB prior to soldering or reflow and holding them in place duringthe soldering or reflow process. After that the pick and place aidingpart will be removed.

The connection system of the present invention thus may have a coaxialconnector that is press fit into a camera housing to connect to a PCBconnector and separate flexible connectors or pins (that may be crimpedonto individual wires or terminals or leads) that are inserted throughthe camera housing to connect to another PCB connector. Optionally, thehousing may include shielding inside the housing between the coaxialpart and the data wires. The PCB ground connection to metal may beachieved via one or more metal fasteners or screws, such as at or nearto the coaxial area or at one or more corners of the PCB. With theconnection of the present invention, there may be direct contact of thePCB header encapsulation to PCB ground.

The camera or sensor may comprise any suitable camera or sensor.Optionally, the camera may comprise a “smart camera” that includes theimaging sensor array and associated circuitry and image processingcircuitry and electrical connectors and the like as part of a cameramodule, such as by utilizing aspects of the vision systems described inInternational Publication Nos. WO 2013/081984 and/or WO 2013/081985,which are hereby incorporated herein by reference in their entireties.

The system includes an image processor operable to process image datacaptured by the camera or cameras, such as for detecting objects orother vehicles or pedestrians or the like in the field of view of one ormore of the cameras. For example, the image processor may comprise anEYEQ2 or EYEQ3 image processing chip available from Mobileye VisionTechnologies Ltd. of Jerusalem, Israel, and may include object detectionsoftware (such as the types described in U.S. Pat. Nos. 7,855,755;7,720,580 and/or 7,038,577, which are hereby incorporated herein byreference in their entireties), and may analyze image data to detectvehicles and/or other objects. Responsive to such image processing, andwhen an object or other vehicle is detected, the system may generate analert to the driver of the vehicle and/or may generate an overlay at thedisplayed image to highlight or enhance display of the detected objector vehicle, in order to enhance the driver's awareness of the detectedobject or vehicle or hazardous condition during a driving maneuver ofthe equipped vehicle.

The vehicle may include any type of sensor or sensors, such as imagingsensors or radar sensors or lidar sensors or ladar sensors or ultrasonicsensors or the like. The imaging sensor or camera may capture image datafor image processing and may comprise any suitable camera or sensingdevice, such as, for example, a two dimensional array of a plurality ofphotosensor elements arranged in at least 640 columns and 480 rows (atleast a 640×480 imaging array, such as a megapixel imaging array or thelike), with a respective lens focusing images onto respective portionsof the array. The photosensor array may comprise a plurality ofphotosensor elements arranged in a photosensor array having rows andcolumns. Preferably, the imaging array has at least 300,000 photosensorelements or pixels, more preferably at least 500,000 photosensorelements or pixels and more preferably at least 1 million photosensorelements or pixels. The imaging array may capture color image data, suchas via spectral filtering at the array, such as via an RGB (red, greenand blue) filter or via a red/red complement filter or such as via anRCC (red, clear, clear) filter or the like. The logic and controlcircuit of the imaging sensor may function in any known manner, and theimage processing and algorithmic processing may comprise any suitablemeans for processing the images and/or image data.

For example, the vision system and/or processing and/or camera and/orcircuitry may utilize aspects described in U.S. Pat. Nos. 8,694,224;7,005,974; 5,760,962; 5,877,897; 5,796,094; 5,949,331; 6,302,545;6,396,397; 6,498,620; 6,523,964; 6,611,202; 6,201,642; 6,690,268;6,717,610; 6,757,109; 6,802,617; 6,806,452; 6,822,563; 6,891,563;6,946,978; 7,859,565; 5,550,677; 5,670,935; 7,881,496; 7,720,580;7,038,577; 6,882,287; 5,929,786 and/or 5,786,772, which are all herebyincorporated herein by reference in their entireties. The system maycommunicate with other communication systems via any suitable means,such as by utilizing aspects of the systems described in InternationalPublication Nos. WO 2010/144900; WO 2013/043661 and/or WO 2013/081985,and/or U.S. Publication No. US-2012-0062743, which are herebyincorporated herein by reference in their entireties.

Optionally, the vision system may include a display for displayingimages captured by one or more of the imaging sensors for viewing by thedriver of the vehicle while the driver is normally operating thevehicle. Optionally, for example, the vision system may include a videodisplay device disposed at or in the interior rearview mirror assemblyof the vehicle, such as by utilizing aspects of the video mirror displaysystems described in U.S. Pat. No. 6,690,268 and/or U.S. Publication No.US-2012-0162427, which are hereby incorporated herein by reference intheir entireties. The video mirror display may comprise any suitabledevices and systems and optionally may utilize aspects of the compassdisplay systems described in U.S. Pat. Nos. 7,370,983; 7,329,013;7,308,341; 7,289,037; 7,249,860; 7,004,593; 4,546,551; 5,699,044;4,953,305; 5,576,687; 5,632,092; 5,677,851; 5,708,410; 5,737,226;5,802,727; 5,878,370; 6,087,953; 6,173,508; 6,222,460; 6,513,252 and/or6,642,851, and/or U.S. Publication No. US-2006-0061008, which are allhereby incorporated herein by reference in their entireties. Optionally,the video mirror display screen or device may be operable to displayimages captured by a rearward viewing camera of the vehicle during areversing maneuver of the vehicle (such as responsive to the vehiclegear actuator being placed in a reverse gear position or the like) toassist the driver in backing up the vehicle, and optionally may beoperable to display the compass heading or directional heading characteror icon when the vehicle is not undertaking a reversing maneuver, suchas when the vehicle is being driven in a forward direction along a road(such as by utilizing aspects of the display system described inInternational Publication No. WO 2012/051500, which is herebyincorporated herein by reference in its entirety).

Optionally, the vision system (utilizing the forward facing camera and arearward facing camera and other cameras disposed at the vehicle withexterior fields of view) may be part of or may provide a display of atop-down view or birds-eye view system of the vehicle or a surround viewat the vehicle, such as by utilizing aspects of the vision systemsdescribed in International Publication Nos. WO 2010/099416; WO2011/028686; WO 2012/075250; WO 2013/019795; WO 2012/075250; WO2012/145822; WO 2013/081985; WO 2013/086249 and/or WO 2013/109869,and/or U.S. Publication No. US-2012-0162427, which are herebyincorporated herein by reference in their entireties.

Optionally, a video mirror display may be disposed rearward of andbehind the reflective element assembly and may comprise a display suchas the types disclosed in U.S. Pat. Nos. 5,530,240; 6,329,925;7,855,755; 7,626,749; 7,581,859; 7,446,650; 7,370,983; 7,338,177;7,274,501; 7,255,451; 7,195,381; 7,184,190; 5,668,663; 5,724,187 and/or6,690,268, and/or in U.S. Publication Nos. US-2006-0061008 and/orUS-2006-0050018, which are all hereby incorporated herein by referencein their entireties.

Changes and modifications in the specifically described embodiments canbe carried out without departing from the principles of the invention,which is intended to be limited only by the scope of the appendedclaims, as interpreted according to the principles of patent lawincluding the doctrine of equivalents.

1. A method of assembling a vehicular camera, the method comprising:providing a front housing portion, wherein the front housing portionaccommodates a lens and an imager; attaching a circuit board at thefront housing portion; providing a rear housing portion, wherein therear housing portion has an outer side and an inner side that isseparated from the outer side by a wall thickness of the rear housingportion; providing a one-piece coaxial connecting element at the rearhousing portion, wherein the coaxial connecting element comprises afirst coaxial cable connector at a first end and a second coaxial cableconnector at a second end opposite the first end; wherein, with thecoaxial connecting element provided at the rear housing portion, thefirst coaxial cable connector extends outward from the outer side of therear housing portion and the second coaxial cable connector extendsinward from the inner side of the rear housing portion; wherein thecircuit board has a third coaxial cable connector established thereat;mating the rear housing portion with the front housing portion to form acamera housing having a cavity, wherein, with the rear housing portionmated with the front housing portion, the circuit board is encased inthe cavity of the camera housing; wherein, as the rear housing portionis mated with the front housing portion, the second coaxial cableconnector engages the third coaxial cable connector at the circuit boardto electrically connect the coaxial connecting element with circuitry atthe circuit board; and wherein the first coaxial cable connector isconfigured to connect to a coaxial cable of a vehicle when the vehicularcamera is disposed at the vehicle.
 2. The method of claim 1, wherein theimager is disposed at an imager circuit board, and wherein providing thefront housing portion comprises attaching the imager circuit board atthe front housing portion such that the imager is aligned with the lens.3. The method of claim 2, wherein attaching the circuit board at thefront housing portion comprises electrically connecting circuitry of thecircuit board to circuitry of the imager circuit board.
 4. The method ofclaim 1, wherein the coaxial connecting element comprises a bent coaxialconnecting element, and wherein a longitudinal axis of the first coaxialcable connector is not parallel to a longitudinal axis of the secondcoaxial cable connector.
 5. The method of claim 1, wherein the coaxialconnecting element comprises a straight coaxial connecting element, andwherein a longitudinal axis of the first coaxial cable connector iscoaxial with a longitudinal axis of the second coaxial cable connector.6. The method of claim 1, wherein providing the rear housing portioncomprises injection molding the rear housing portion, and whereinproviding the coaxial connecting element comprises insert-molding thecoaxial connecting element in the rear housing portion during injectionmolding of the rear housing portion.
 7. The method of claim 1, whereinproviding the coaxial connecting element comprises inserting the coaxialconnecting element into the rear housing portion so that the coaxialconnecting element is press-fit at the rear housing portion.
 8. Themethod of claim 1, wherein the rear housing portion further comprises amulti-pin connector having a plurality of terminals, and wherein theplurality of terminals extend inward from the inner side of the rearhousing portion to electrically connect to terminals of a headerconnector of the circuit board for electrically connecting to circuitryat the circuit board, and wherein the multi-pin connector, at the outerside of the rear housing portion, is configured to electrically connectto a plurality of terminals that electrically connects to a wire of thevehicle when the vehicular camera is disposed at the vehicle.
 9. Themethod of claim 8, wherein the coaxial connecting element and themulti-pin connector are formed adjacent one another as part of the rearhousing portion.
 10. The method of claim 8, wherein the coaxialconnecting element and the multi-pin connector are spaced apart from oneanother at the rear housing portion.
 11. The method of claim 8, whereinthe coaxial connecting element and the multi-pin connector are at leastin part molded at the rear housing portion.
 12. The method of claim 8,comprising disposing an electrically conductive shield at leastpartially around the header connector and in electrical connection withcircuitry at the circuit board, and comprising engaging a clampingelement with the electrically conductive shield when the terminalsengage the header connector as the rear housing portion is mated withthe front housing portion, wherein engagement of the clamping elementand the electrically conductive shield provides enhanced grounding ofthe terminals of the multi-pin connector with circuitry at the circuitboard.
 13. The method of claim 1, wherein a connecting end of thecoaxial cable comprises a laterally flexible core pin, and wherein adielectric element is disposed at least partially along the laterallyflexible core pin to limit lateral movement of the laterally flexiblecore pin within the first coaxial cable connector of the coaxialconnecting element when the first coaxial cable connector is connectedto the coaxial cable.
 14. The method of claim 1, wherein a connectingend of the coaxial cable comprises a crimped ferule that is received inthe first coaxial cable connector at the rear housing portion when thefirst coaxial cable connector is connected to the coaxial cable of thevehicle when the vehicular camera is disposed at the vehicle.
 15. Themethod of claim 1, wherein the first coaxial cable connector includes aninner connecting element and an outer connecting element that iselectrically isolated from and at least partially circumscribes theinner connecting element of the first coaxial cable connector, andwherein the second coaxial cable connector includes an inner connectingelement and an outer connecting element that is electrically isolatedfrom and at least partially circumscribes the inner connecting elementof the second coaxial cable connector, and wherein the third coaxialcable connector includes an inner connecting element and an outerconnecting element that is electrically isolated from and at leastpartially circumscribes the inner connecting element of the thirdcoaxial cable connector.
 16. The method of claim 15, wherein the innerconnecting element of the second coaxial cable connector comprises aspring-loaded element that is biased towards an extended state toenhance electrical connection to the inner connecting element of thethird coaxial cable connector at the circuit board when the rear housingportion is mated with the front housing portion.
 17. The method of claim15, wherein the imager comprises at least 1 million photosensor elementsarranged in rows and columns in a two dimensional array.
 18. The methodof claim 17, wherein, when the vehicular camera is disposed at thevehicle and is operated, the imager captures image data for a surroundview system of the vehicle.
 19. The method of claim 1, wherein providingthe coaxial connecting element comprises providing a rigid one-piececoaxial connecting element.
 20. A method of assembling a vehicularcamera, the method comprising: providing a front housing portion,wherein the front housing portion accommodates a lens and an imager;wherein the imager comprises at least 1 million photosensor elementsarranged in rows and columns in a two dimensional array; attaching acircuit board at the front housing portion; providing a rear housingportion, wherein the rear housing portion has an outer side and an innerside that is separated from the outer side by a wall thickness of therear housing portion; providing a one-piece coaxial connecting elementat the rear housing portion, wherein the coaxial connecting elementcomprises a first coaxial cable connector at a first end and a secondcoaxial cable connector at a second end opposite the first end; wherein,with the coaxial connecting element provided at the rear housingportion, the first coaxial cable connector extends outward from theouter side of the rear housing portion and the second coaxial cableconnector extends inward from the inner side of the rear housingportion; wherein the coaxial connecting element comprises a straightcoaxial connecting element, and wherein a longitudinal axis of the firstcoaxial cable connector is coaxial with a longitudinal axis of thesecond coaxial cable connector; wherein the circuit board has a thirdcoaxial cable connector established thereat; wherein the first coaxialcable connector includes an inner connecting element and an outerconnecting element that is electrically isolated from and at leastpartially circumscribes the inner connecting element of the firstcoaxial cable connector, and wherein the second coaxial cable connectorincludes an inner connecting element and an outer connecting elementthat is electrically isolated from and at least partially circumscribesthe inner connecting element of the second coaxial cable connector, andwherein the third coaxial cable connector includes an inner connectingelement and an outer connecting element that is electrically isolatedfrom and at least partially circumscribes the inner connecting elementof the third coaxial cable connector; mating the rear housing portionwith the front housing portion to form a camera housing having a cavity,wherein, with the rear housing portion mated with the front housingportion, the circuit board is encased in the cavity of the camerahousing; wherein, as the rear housing portion is mated with the fronthousing portion, the second coaxial cable connector engages the thirdcoaxial cable connector at the circuit board to electrically connect thecoaxial connecting element with circuitry at the circuit board; andwherein the first coaxial cable connector is configured to connect to acoaxial cable of a vehicle when the vehicular camera is disposed at thevehicle.
 21. The method of claim 20, wherein the imager is disposed atan imager circuit board, and wherein providing the front housing portioncomprises attaching the imager circuit board at the front housingportion such that the imager is aligned with the lens.
 22. The method ofclaim 21, wherein attaching the circuit board at the front housingportion comprises electrically connecting circuitry of the circuit boardto circuitry of the imager circuit board.
 23. The method of claim 20,wherein the inner connecting element of the second coaxial cableconnector comprises a spring-loaded element that is biased towards anextended state to enhance electrical connection to the inner connectingelement of the third coaxial cable connector at the circuit board whenthe rear housing portion is mated with the front housing portion. 24.The method of claim 20, wherein providing the coaxial connecting elementcomprises providing a rigid one-piece coaxial connecting element.
 25. Amethod of assembling a vehicular camera, the method comprising:providing a front housing portion, wherein the front housing portionaccommodates a lens and an imager; wherein the imager comprises at least1 million photosensor elements arranged in rows and columns in a twodimensional array; attaching a circuit board at the front housingportion; providing a rear housing portion, wherein the rear housingportion has an outer side and an inner side that is separated from theouter side by a wall thickness of the rear housing portion; providing aone-piece coaxial connecting element at the rear housing portion,wherein the coaxial connecting element comprises a first coaxial cableconnector at a first end and a second coaxial cable connector at asecond end opposite the first end; wherein, with the coaxial connectingelement provided at the rear housing portion, the first coaxial cableconnector extends outward from the outer side of the rear housingportion and the second coaxial cable connector extends inward from theinner side of the rear housing portion; wherein the coaxial connectingelement comprises a bent coaxial connecting element, and wherein alongitudinal axis of the first coaxial cable connector is not parallelto a longitudinal axis of the second coaxial cable connector; whereinthe circuit board has a third coaxial cable connector establishedthereat; wherein the first coaxial cable connector includes an innerconnecting element and an outer connecting element that is electricallyisolated from and at least partially circumscribes the inner connectingelement of the first coaxial cable connector, and wherein the secondcoaxial cable connector includes an inner connecting element and anouter connecting element that is electrically isolated from and at leastpartially circumscribes the inner connecting element of the secondcoaxial cable connector, and wherein the third coaxial cable connectorincludes an inner connecting element and an outer connecting elementthat is electrically isolated from and at least partially circumscribesthe inner connecting element of the third coaxial cable connector;mating the rear housing portion with the front housing portion to form acamera housing having a cavity, wherein, with the rear housing portionmated with the front housing portion, the circuit board is encased inthe cavity of the camera housing; wherein, as the rear housing portionis mated with the front housing portion, the second coaxial cableconnector engages the third coaxial cable connector at the circuit boardto electrically connect the coaxial connecting element with circuitry atthe circuit board; and wherein the first coaxial cable connector isconfigured to connect to a coaxial cable of a vehicle when the vehicularcamera is disposed at the vehicle.
 26. The method of claim 25, whereinthe imager is disposed at an imager circuit board, and wherein providingthe front housing portion comprises attaching the imager circuit boardat the front housing portion such that the imager is aligned with thelens.
 27. The method of claim 26, wherein attaching the circuit board atthe front housing portion comprises electrically connecting circuitry ofthe circuit board to circuitry of the imager circuit board.
 28. Themethod of claim 25, wherein the inner connecting element of the secondcoaxial cable connector comprises a spring-loaded element that is biasedtowards an extended state to enhance electrical connection to the innerconnecting element of the third coaxial cable connector at the circuitboard when the rear housing portion is mated with the front housingportion.
 29. The method of claim 25, wherein providing the coaxialconnecting element comprises providing a rigid one-piece coaxialconnecting element.